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Bellmer improves the sludge dewatering plants at Hamburger Hungaria
Bellmer was contracted for the new sludge dewatering plant (reject - and organic sludge) for the PM 7 at Hamburger Hungaria Dunaújváros, the largest paper mill in Hungary. At this project many departements and subsidiaries of the Bellmer Group have worked successfully together. Peppered with numerous technical Bellmer highlights the new plant can reach higher dry solids contents, higher production, lower filtrate load, lower polymer consumption and much lower energy consumption.

Hamburger Hungaria Kft is a subsidiary company of the Austrian family-owned business Prinzhorn Holding. An important milestone in the production and product range enlargement strategy of the Prinzhorn Group was the foundation of the company Hamburger Hungaria Kft. Hamburgers main objective is, to continue the traditional papermaking at Dunapack in Hungary in the long term.
The company of Hamburger Hungaria Kft, Dunaújváros is located about 70 km south of the capital Budapest in the Central Transdanubia region. The area has been inhabited since the Bronze Age. Dunaújváros is a University City and has a population of about 55,000.

Hamburger Hungaria is a quality leader and well established partner for the corrugated board industry in Central and Eastern Europe since many years. The paper mill produces corrugated base paper on base of 100% waste paper. The raw material for paper production, appropriately selected recycled paper, which originates mainly from the Hungarian market.
The two paper machines PM3 and PM7 recycle around 650,000 tonnes of waste paper a year. At the same time they apply as one of the most important environmental investments in Hungary. They were awarded with the environmental prize "Ökoindustria 2013".

In December 2014, the company decided to improve its existing sludge dewatering equipment of PM7 and WWT. With the tender to increase the capacity and the dry solids content of reject- and organic sludge dewatering Hamburger Hungaria Kft could be sure to have the full attention of all providers.

In the future the reject- and organic sludge should be burned in a nascent power plant with combined heat and power. So it was a challenge for Bellmer to offer a complete solution with the target of the highest dry solids content. In addition to the experience as a market leader in the area of Separation Technology (more than 5,000 references) and the necessary technical know-how the flexibility of a medium-sized company (since 1842, 6. generation family-owned) was essential for Hamburger to award the contract.

In September 2015 Bellmer could finally take the order. In the meantime a plant consisting of a screw press AKUPRESS®BX, WinklePress™ WP Green 4 IX, screw conveyors, automation and engineering was delivered and successfully put into operation.
A new Bellmer WinklePress WP Green 4 IX in the waste water treatment of PM7

In their WWT plant Hamburger Hungaria Kft operates a centrifuge with a drum thickener, a chamber press, as well as a twin wire press. All of these dewatering systems don´t work to the customer’s satisfaction.
Major challenges were the low dry solids contents and above all the high energy and service costs.
Bellmer and Hamburger have developed a concept, which meets the arising amounts of organic sludge by about 67 m³ up to max. 83 m³ per hour and dry solids contents between 1.2-1.5%.
The sludge is a mixture of biological and chemical percentages out of the multi-stage wastewater treatment.
The delivery includes a new WinklePress™ WP Green 4 IX with a working width of 2.5 m and a special sludge conveyor system with built-in, fully automatic discharge system
The new, enhanced concept of the WinklePress™ with 5 dewatering stages is particularly suited to achieve highest dry solids contents and low polymer consumption. This is especially important for sludges with low press stability and a high organic content, but also improves the dewatering results of other sludges. Higher dry solids contents can be achieved thanks to the optimized roller configuration. The single roller gradations have been revised and the pressing time within the machine considerably increased. With the accumulated organic sludge mixture the WinklePress™ WP Green 4 IX achieves dry solids contents of about 25%.
New Bellmer Kufferath AKUPRESS®BX 1100 LL-H in the reject and organic sludge line PM7

Problems with the existing screw press of a competitor especially arised, when the mechanical sludge was mixed with organic sludge. During this operation the achieved capacity and the final dry solids contents were not satisfying for Hamburger. Therefore the existing sludge dewatering equipment consisting of disc thickener and screw press should be optimized.

Project objectives were a significant increase in production to at least 70 TPD and at the same time the increase of the final dry solids content of the dewatered sludge.
It has been determined in the context of engineering that the used prethickener still meets the new requirements and thus should be integrated into the new concept. The use of a modern screw press for the dewatering of the incidental sludges was rather in the focus of consideration. Due to the product datas and quantities Hamburger choose the Bellmer Kufferath screw press AKUPRESS®BX 1100 LL-H. Hereby, any arising sludge amounts can be processed easily. Depending on the sludge composition final dry solids contents up to 60% can be achieved.
he scope of supply of Bellmer Kufferath includes a new screw press AKUPRESS®BX 1100 LL-H with a screw diameter of 1,100 mm, its torque controller, the complete engineering, commissioning and training of the installed equipment.

Partnership and competence as the key to success

Close cooperation and coordination at the plant concepts, when placing the order to installation and start-up were essential for the success of this project.
With the implementation of the above-mentioned points and the exchange of the existing systems with the new Bellmer WinklePress™ WP Green 4 IX as well as the AKUPRESS®BX 1100 LL-H the increase in production and dry solids content, the saving of polymer and energy costs, as well as a simultaneous increase of the operational stability and reliability are possible.

Author
Artur Salawa
Sales Manager
Separation Technology